Small-arms ammunition with non-brass casing and non-lead projectile

ABSTRACT

A small arms ammunition round comprises a non-brass casing comprising stainless steel and a non-lead projectile housed within the casing, the non-lead projectile comprising a matrix of at least one epoxy, at least one non-epoxy polymer, and copper. The casing includes a stainless steel shell housing and an aluminum (or stainless steel) primer housing which are press-fit together. The projectile has a tapered nose with spiral flutes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Non-Provisionalpatent application Ser. No. 16/046,307 filed Jul. 26, 2018; which claimspriority benefit of U.S. Provisional Patent Application Ser. No.62/537,632 filed Jul. 27, 2017, the entirety of which is herebyincorporated herein by reference.

BACKGROUND

Typical ammunition for rifles and handguns consists of a generallytubular brass shell casing bearing a lead bullet, with the tubularcasing housing a percussion-responsive cap (primer) and a propellantcharge disposed within the casing between the primer and the bullet. Thedesire for simplicity in manufacture, long shelf life, dimensionalstability, and other factors, has led to widespread adoption of brass asthe casing material and lead as the projectile.

Published EP patent application WO1983000213A1 of Palcher describes theuse of polymeric materials in making the casing. The application evendescribes the possibility that the bullet (the projectile) itself can bepartially formed of a polymeric material. The Palcher applicationdescribes that the conventional brass shell is rigid and hard, its sidewall is very thin, and the whole is relatively inelastic. The Palcherapplication describes that the disclosed shell casings are fabricatedwith polymeric materials that exhibit high degrees of elongation,relatively high degrees of flexibility, and have different shapes.

The Palcher application describes that the preferred casing material isa polymer, being a thermoplastic rather than a thermosetting polymer,which has a high strength and is heat and flame resistant. Inparticular, the Palcher application describes that preferred casingmaterials are polysulfone, polyimide-amide and polyethylene sulfone.

U.S. Pat. No. 9,939,236 of Drobockyi et al discloses an alternativecasing for use in a cartridge for a firearm, in which the casingcomprises a sleeve and an attached base made of stainless steel. Thesleeve is formed with a mouth for holding a bullet and an opposingbulkhead from which extends a nipple. The end of the nipple is flaredradially outwardly within a passageway of the base, to form a specialconfiguration lip and first seal. The nipple is shaped to make a secondseal when press fitted into the passageway. A bulkhead is formed with acircumferential wave or ridge. The '236 Patent describes that the sleevepreferably is made from austenitic stainless steel that is worked tohave differential hardness and magnetic properties along the sleevelength, with the nipple being of lesser hardness.

The Palcher application and the '236 Patent of Drobockyi et al addressdifferent problems in the field of firearms and each has their owntechnical hurdles to overcome in addressing those different problems.Indeed, as noted in Palcher, this is not a mere substitution of physicalmaterials. The brass shell is rigid and hard. Its side wall is verythin, and the whole is relatively inelastic. Shell casings, according tothe Palcher's disclosure, are fabricated with polymeric materials thatexhibit high degrees of elongation without failure, relatively highdegrees of flexibility, and different shapes as compared to thetraditional brass casing. Similarly, various changes in the design ofthe shell are needed to make the stainless steel shell (casing) of the'236 Patent of Drobockyi workable.

SUMMARY OF THE INVENTION

In a first preferred example form, the present invention comprises asmall arms ammunition round having a non-brass casing and a non-leadprojectile housed within the casing. Preferably, the non-brass casingincludes stainless steel and the non-lead projectile includes a matrixof at least one epoxy, at least one non-epoxy polymer, and copper.

Preferably, the casing comprises a stainless steel shell housing and analuminum primer housing which are press-fit together.

Also optionally, the projectile has a tapered nose with spiral flutes.

In a second preferred example form, the present invention comprises asmall arms ammunition round having a non-brass casing and a non-leadprojectile housed within the casing.

Preferably, the non-brass casing comprises a stainless steel casing.Preferably, the non-brass casing also comprises an aluminum casing. Mostpreferably, the stainless steel casing is for housing the projectile andthe aluminum casing is for housing a primer, with the stainless steelcasing and the aluminum casing being press-fit together.

Also optionally, the projectile has a tapered nose with spiral flutes.

Optionally, the primer base could also be made of stainless steel, suchas a 416 stainless steel alloy, for example.

Also optionally, the projectile can be constructed with hBN (hexagonalBoron Nitride) powder to achieve a poly/molded projectile. Thisultra-fine hBN powder acts as a friction-reduction agent when applied,through an optional steel/ceramic shot vibration/shot peening process,into the pores of the projectile. The use of hBN powder can providemultiple advantages in this application, including: reduced frictionbetween the projectile and the barrel rifling, thus decreasing pressure,reducing barrel wear, increasing velocity, improving accuracy andminimizing the extreme velocity spread between many rounds.

With these constructions, a novel small arms round is provided,including an all stainless steel/aluminum cased, polycarbonate/coppertipped, high-performance cartridge. The resulting round is lightweightand exhibits high performance. For example, the novel small armsrounds/cartridges reduce weight compared to heavy traditional ammo by asmuch as 30-60%. Moreover, the projectiles exhibit a velocity increase ofabout 15-30% over conventional rounds, and reduce recoil by 10-25%.Advantageously, the novel rounds eliminate lead and copper fouling inthe gun barrels.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a schematic plan view of a small arms round including anon-brass shell casing and a non-lead projectile according to an exampleform of the present invention.

FIG. 2 is a schematic plan view of a non-lead projectile portion of thesmall arms round of FIG. 1.

FIG. 3 is a schematic end view of a non-lead projectile portion of thesmall arms round of FIG. 1.

FIG. 4 is a schematic perspective view of a small arms round including anon-lead projectile portion in an alternate example form of the presentinvention.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

FIG. 1 shows an example embodiment of a small arms round according toone form of the present invention. The example small arms ammunitionround 100 shown in FIG. 1 includes a non-brass casing 110 and a non-leadprojectile 150 housed within the casing. Preferably, the non-brasscasing 110 includes stainless steel and the non-lead projectile 150includes a matrix of at least one epoxy, at least one non-epoxy polymer,and copper. Optionally, the non-epoxy polymer can include nylon (eitherentirely or as a component thereof). Preferably, the casing 110comprises a stainless steel shell housing 111 and an aluminum primerhousing 112 which are press-fit together adjacent joint 115.

Also preferably, the projectile has a tapered nose with spiral flutes.As generally described in published US Patent Application Number20160231093 of Lemke, the projectile 150 has an outer geometrycomprising several notches 152-154 extending in a longitudinal direction(i.e., axial direction). Notches 152-154 are present in a number equalto or greater than two and preferably are disposed in such a manner asto avoid an imbalance of the rotation of projectile 150 about itsdissecting axis, which could cause a deviation of a flight path 159. Insome embodiments, the number of notches is three. However, the number ofnotches can be four or another quantity.

As further shown in FIG. 1, exemplary projectile 150 has a notchconfiguration that increases an outer surface area of the end portion155 of projectile 150. Each notch 152-154 can comprise a first notchsurface portion in combination with a second notch surface portion(which can be a spherical surface). The spherical surface portion makesthe notched projectile structurally stronger so that when projectile 150hits a soft element, it avoids the formation and propagation of crackswhich would tend to cause it to decompose into small fragments.

In some embodiments, projectile 150 can be manufactured by injectionmolding a polymeric material (e.g., a polyamide) filled with metalparticles. In some embodiments, projectile 150 can be manufactured bysintering and/or machining with or without electrochemical coating.Preferably, in some embodiments, projectile 150 is manufactured with abase material that will not deform easily upon impact and decompose intofragments upon impact, such as a violent impact against a hard surface,to ensure that it remains a frangible projectile 150 by definition.

As shown in FIG. 2, in some embodiments of the present invention,projectile 150 travels after a shot, making a trajectory 159 with arotational movement 160 along axis of projectile 150 so as to ensurestability during flight. On impact, energy of projectile 150 makesprojectile 150 decompose into fragments, which are thrown in variousdirections, such as directions 161, 162, 163, producing only a smalldamaged area on a hard surface. The production of such fragmentsprevents projectile 150 from ricocheting uncontrollably and reaching anunintended target.

The novel projectile has a degree of “engineered frangibility” which bydesign means that it will penetrate most “hard surfaces” such as a thinmetal car door, an automotive windshield, wood, a tree trunk of modestsize, building walls of drywall and wood studs, even mild steel plate(although the windshield and mild steel plate will cause deformation ofthe nose of the projectile to some degree). When the projectileencounters these types of somewhat “hard surfaces”, it tends to retainits rotation and its shape (except as noted) and tends to penetrate in amanner similar to a normal projectile. These are “hard surfaces”, butcan be penetrated by small arms fire to some degree.

There are other “hard surfaces” which are more impenetrable to smallarms fire. Examples of such include hardened steel competition targets,concrete walls, sidewalks, stone, heavy cast iron, thick steel plating,thick bullet-proof glass, and similar materials, which are generallyimpenetrable to small arms fire. When the projectile encounters thesetruly “hardened surfaces”, typically it then loses its rotationalmomentum and all penetration quickly halts, as the projectile fragmentsinto many tiny particles.

In some embodiments of the present invention, as projectile 150 travelsalong path 159 and, at the same time, it undergoes a rotational movement160 around axis of projectile 150 to ensure stability during flight.Upon impact on a relatively soft target, penetration occurs due to theprojectile velocity and dampening of the rotational movement. Dampeningis due to the effect of the soft element resistance cut by notches 152,153, 154 of projectile 150 more or less acting as if it were a drill.Dampening tends to cause an increase in resistance of projectile 150 andan increase in the amount of damaged tissue, increasing the amount oftransmitted energy (i.e., kinetic and rotational) and the size of thedamaged area in the form of a temporary cavity.

In some embodiments, the rear or bottom of projectile 150, opposite thetip 158 in the longitudinal direction, can have a slightly conicalgeometry, also called a “boat tail”, to increase the aerodynamics ofprojectile 150.

In a second preferred example form, the present invention comprises asmall arms ammunition round having a non-brass casing and a non-leadprojectile housed within the casing.

Preferably, the non-brass casing comprises at least a stainless steelcasing portion. Preferably, the non-brass casing also comprises analuminum casing portion. Most preferably, the stainless steel casing isprovided for housing the projectile and the aluminum casing is providedfor housing a primer, with the stainless steel casing portion and thealuminum casing portion being press-fit together. Also preferably, theprojectile has a tapered nose with spiral flutes.

FIG. 4 shows an alternative form of the present invention. The examplesmall arms ammunition round 400 shown in FIG. 4 includes a non-brasscasing 410 including a stainless steel projectile housing portion 411and an aluminum primer housing portion 412 which are press-fit togetheradjacent joint 415. A non-lead projectile 450 is housed within thecasing (within projectile housing portion 411). Preferably, thenon-brass casing portion 410 includes a stainless steel portion and thenon-lead projectile 450 includes a matrix of at least one epoxy, atleast one non-epoxy polymer, and copper. Optionally, the non-epoxypolymer can include nylon (either entirely or as a component thereof).Optionally, the nose portion 452 of the projectile 450 is smoothlytapered and does not bear the spiral flutes of the previous example.

With these constructions, a novel small arms round is provided,including an all stainless steel/aluminum cased, polycarbonate/coppertipped, high-performance cartridge. The resulting round is lightweightand exhibits high performance. For example, the novel small armsrounds/cartridges reduce weight compared to heavy traditional ammo by asmuch as 30-60%. Moreover, the projectiles exhibit a velocity increase ofabout 15-30% over conventional rounds, and reduce recoil by 10-25%. Thisincrease in velocity is believed to be due to the lighter weight (lowermass) being accelerated by comparably similar forces developed by thesimilar amounts of gunpowder contained in the casings. Advantageously,the novel rounds eliminate lead and copper fouling in the gun barrels.

Advantageously, the present invention provides a substantial weightsavings per round, which can be extremely beneficial in militaryapplications. For example, a soldier that carries 200 rounds of 5.56 mmammunition into battle at a weight of about 5.2 lbs can obviously carrya limited supply of ammunition. The present invention allows the soldierto carry the same number of rounds at half the weight or carry the sameweight but twice the amount of ammunition (twice the number of rounds).Carrying twice the number of rounds can mean the difference between lifeand death in that the additional rounds can significantly extend thesoldier's ability to fight.

Moreover, police often must carry a certain volume of ammo on theirperson. The average 45 ACP with 230 grain bullet weighs 325 grains, 20.9grams, or 0.7 ounces. If required to carry 9 cartridges in the gun andtwo extra clips, the total weight is 1 lb, 3 oz of bullet weight.However, if the same policeman was carrying the novel ammunitionaccording to the present invention, with its sleek, lightweightstainless steel and aluminum casing and the projectile, total cartridgeweight would be 8.4 oz., a weight savings of 55%.

Also, military armory engineers have been trying to develop a load forboth .223 and .308 calibers that will shoot with deadly force up to 300yards and then die out quickly after that range, thereby reducingdown-range liability. Up until now, they have not been able to find asatisfactory load to perform in such a manner. The present inventionaddresses this need as well.

Also, U.S. military and many law enforcement agencies have a minimumPower Factor (PF) (similar to KE—Kinetic Energy) for all ammunition inservice or issue. That minimum PF is 125. Known frangible bulletstypically cannot meet PF minimum requirements, with most known testingfalling below the minimum PF of 125. It is believed that the presentinvention with a more efficient casing and effective projectile willachieve PF of greater than 125.

Optionally, the aluminum casing portion can be pure aluminum or can bean aluminum alloy. For example, advantageously, the aluminum alloycasing can comprise 7075 aluminum alloy. Also, the aluminum alloy casingcan comprise 7068 aluminum alloy. Those skilled in the art willappreciate that other aluminum alloys or pure or nearly pure aluminumcan be employed, as selected by the skilled designer.

Optionally, the non-lead matrix (Poly/Copper Matrix) can comprise one ormore of the following materials: polymers; epoxies; nylon; copperparticles; tungsten particles; depleted uranium; and/or otherarmor-piercing “heavy” metals and materials.

Optionally, the stainless steel non-brass casing (the stainless steelcasing portion) can comprise one or more of: stainless steel; highnickel content stainless steel; high chromium stainless steel; and/orother non-brass metals and materials.

Optionally, the aluminum primer portion of the non-brass casing cancomprise one or more of: aluminum; hardened aluminum; aircraft-grade7XXX Series aluminum alloy(s) (zinc is a primary alloying agent for thisseries, and when magnesium is added in a smaller amount, the result is aheat-treatable, very high strength alloy. Other elements such as copperand chromium may also be added in small quantities. The most commonlyknown alloys are 7050 and 7075, which are widely used in the aircraftindustry.) The aluminum could also be a more or less pure aluminum whichis then nickel plated. The aluminum could also be replaced with othernon-brass materials, such as chromium molybnium which is nickel plated;mild steel which is nickel plated; and stainless steel. Note that nickelplating of non-stainless steel base materials is performed to preventelectrolysis of dissimilar metals.

In an example commercial embodiment actually constructed and tested, thenon-lead matrix (Poly/Copper Matrix) comprises 80% powdered copper, 20%polymer, epoxy and nylon. In that same example commercial embodimentactually constructed and tested, the stainless steel non-brass casingportion comprises a 316 grade of stainless steel. Further, in that sameexample commercial embodiment actually constructed and tested, thealuminum primer portion comprises 7078 aerospace grade aluminum alloy.

Optionally, the molded projectile could be made with an insert of a basematerial made of a solid, non-fragmenting material. In this case, a typeof a “hybrid” frangible projectile could be provided, with anarmor-piercing core or insert made of tungsten or depleted uranium, orother hardened or “heavy” metals and materials.

Optionally, the novel casing and projectile can be combined withhydrophilic lead-free primers. Such would result in an entirelylead-free ammunition, including the primer. As can be appreciated, theconventional ignition material contained in traditional primers containslead and represents a serious environmental concern.

Example Calibers

The present invention can be provided in a variety of small armscalibers, including:

9 mm Luger (9×19 mm)

.22 LR

.22 WMR

.380 Auto

38 Special

.357 Sig

.357 Magnum

.40 S&W

10 MM

.45 ACP

4.6 mm×30 mm

5.56 mm/.223R

6.5 mm Grendel

6.5 Creedmoor

6.8 mmR

.300 AAC B/O

7.62../.308W

.30-06 Sgfd.

.338 Lapua

.338 Norma

.50 BMG

.50 Russian

20 MM A/A (Anti-Aircraft)

30 MM A/A

Testing, Generally:

The novel ammunition has completed the approval process of the novel 9mm Engagement Extreme (EE) and 9 mm Cross Trainer (CT) ammunition. Thistesting included shooting 11,400 cartridges of the novel 9 mm EE and11,600 cartridges of the novel 9 mm CT through a total of 18 pistols and8 shooters. The shooters represented a range of consumers includingexperienced and inexperienced men and women of varying ages. The novel 9mm EE passed with an overall pass rate of 99.96% and the novel 9 mm CTpassed with an overall pass rate of 99.96%, as well.

The ammunition passed the Pressure and Velocity threshold testing. After100 cartridges, the novel 9 mm EE recorded an average velocity of 1,552FPS with a SD of 11 and ES of 40 FPS. The novel 9 mm CT recorded anaverage pressure of 37,541 PSI with a SD of 811 and ES of 3,837 PSI.After 100 cartridges, the novel 9 mm EE recorded an average velocity of1,575 FPS with a SD of 11 and ES of 42 FPS. The novel 9 mm EE recordedan average pressure of 36,740 PSI with a SD of 816 and ES of 3,338 PSI.

Pressure and Velocity Testing:

Pressure:

A testing standard for pressure is that the pressure should not exceed aMaximum Probably Sample Mean (MPSM) and also should not exceed MaximumExtreme Variation (MEV). As defined by the Sporting Arms and AmmunitionManufacturer's Institute (SAAMI), the MPSM for standard pressure 9 mmLuger is 37,800 PSI. The novel 9 mm CT averaged 37,541 PSI and the novel9 mm EE averaged 36,740 PSI, which is below the MPSM. The MEV is definedby SAAMI as 5.16 times the standard deviation of the sample. MEV for thenovel 9 mm CT is calculated to be 4,189 PSI, but our ES was 3,837 PSI.The MEV for the novel 9 mm EE is calculated to be 4,211 PSI, but our ESwas 3,338 PSI. Both standards of MPSM and MEV were met.

Velocity:

A testing standard for velocity is that the velocity should not varymore than 5% of the mean. 5% of the average velocity for the novel 9 mmCT is 78 FPS and for the novel 9 mm EE is 79 FPS. The tested extremespreads for velocity were 40 and 42, respectively.

Accuracy Testing:

A testing standard for accuracy is that the ammunition must be capableof grouping five consecutive shots in a group 6″ or less at 25 yards,from a rest with optical magnification allowed.

Weapon Used:

The test weapon used was an STI DVC Open chambered in 9 mm. This pistolhas a 5.4″ barrel and has mounted C-More 6MOA Dot Sight. This gun waschosen due to the sight and ease of aim.

Set Up:

At a local shooting range, targets were mounted to shoot out to 25yards. We used the STI DVC Open, and the range tray as a rest (restingthe bottom of the magazine on the tray with no muzzle support). Fiveconsecutive shots were then fired.

Results:

Using the STI DVC Open, we were able to obtain a 3¼″ group with thenovel 9 mm CT and a 1¼″ group with the novel 9 mm EE. The novel 9 mm+PEE came in with a 1⅞″ group and the novel 9 mm+P CT shot a 3⅙″ group.The accuracy of these cartridges passes the standard.

Function/Jury Testing:

A testing standard for Function/Jury Testing is that for each newproduct, a minimum of 10,000 cartridges is to be shot, through a minimumof ten weapons, with at least 6 testers/jurors. To meet the standard,the overall pass rate must be at or above 99.83%. Shooters are to berepresentative of the typical consumer, ranging from inexperienced menand women, to experienced men and women of varying sizes. Shooters areto shoot from four positions, for a total of 200 cartridges per shooter(50 per position). We used a total of eight jurors and a total of 18pistols.

Positions (CT & EE):

50 Cartridges two handed, arms extended; 50 Cartridges two handed, armsslightly bent; 50 Cartridges one handed, strong hand; 50 Cartridges onehanded, weak hand.

Results:

A total of 11,600 cartridges of the novel 9 mm CT were fired. In thosecartridges, there were a total of five failures. No one gun had morethan one failure. This gives a 99.96% pass rate.

A total of 11,400 cartridges of the novel 9 mm EE were fired. In thosecartridges, there were a total of five failures. No one gun had morethan one failure. This gives a 99.96% pass rate.

Ballistic Gel Testing:

Various examples of the novel ammunition were tested in gel, includingthe novel 9 mm CT, the novel 9 mm EE, the novel 9 mm+P CT, and the novel9 mm+P EE, all through bare 10% Ballistic Ordinance Gelatin. The novel 9mm+P EE ammunition was then tested through two intermediatebarriers—6061 T6 Aluminum and car windshield. The aluminum waspositioned 10″ in front of the gel. The windshield was positioned 10″ infront of the gel at a compound angle.

Results:

The novel 9 mm EE—Bare Gel obtained 16¾″ of penetration, with 3″ indiameter cavitation, and 100% weight retention (no fragmentation).

The novel 9 mm CT—Bare Gel obtained 19¼″ of penetration, 1⅞″ in diametercavitation, and 100% weight retention (no fragmentation).

The novel 9 mm EE+P—Bare Gel obtained 16¾″ of penetration, 3¾″ indiameter cavitation, and 100% Weight retention (no fragmentation).

The novel 9 mm CT+P—Bare Gel obtained 19¼″ of penetration, approximately2″ in diameter cavitation, and 100% Weight retention (no fragmentation).

The novel 9 mm EE+P—6061 T6 Aluminum obtained 13¾″ of penetration,approximately 3″ in diameter cavitation, and 91% Weight retention (somefragmentation).

The novel 9 mm EE+P—Car Windshield obtained 12¼″ of penetration,approximately 1¾″ in diameter cavitation, and 70.5% Weight retention(fragmentation). Note: While shooting the windshield, it is possible toshoot through the same hole, or a weakened area of the windshield ofglass and the bullet does not fragment.

Testing Summary:

After firing a total of 23,000 cartridges, with 18 pistols, and 8shooters, the novel 9 mm CT and the novel 9 mm EE successfully passedthe jury test. Between the two tested cartridges, there was an overallpass rate of 99.9565% pass rate. This ammunition has also passed theconsistency and accuracy standards. These both are solid cartridges.

The novel ammunition described herein provides high performance in partdue to elimination of the brass shell. Brass, because of its soft,malleable nature, absorbs a significant amount of energy at the time ofthe round being fired. The thick brass case walls and shell base stretchand expand, resulting in somewhat compromised velocity. The novelstainless steel case, being less prone to stretching and deforming, andexhibiting superior hardness and having a greater modulus of elasticity,does not absorb nearly as much energy from the shot, resulting in moreenergy pushing the projectile and much higher velocities withoutincreased pressures.

As described herein, the novel ammunition achieves a synergisticadvantageous result. For example, if a standard 5.56/223 brass case ischarged with a maximum amount of gunpowder (SAAMI max psi) and the 35 grpoly/copper projectile is loaded, the 35 gr bullet produces 3810 fps outof a test receiver rifle. That is what testing revealed.

Now, the novel ammunition, charged with the identical type and weight ofgunpowder, loaded with the same 35 gr poly/copper bullet, achieves asignificant improvement in performance. Using the same test gun, thesame gunpowder, everything as identical as can be achieved—the novelammunition fires at a speed of 4120 fps with slightly less pressure.This is an increase of 310 fps, which is more than an 8% increase inperformance gained from superior cartridge components, while using thesame gunpowder. An 8% increase is very significant.

As is well known in the art, to achieve a performance of about 2% inincreased velocity usually requires a “magnum” version of ammo (greatergunpowder load). Example: 30-06 Sgfd shoots a 180 grain bullet at 2810fps. But the venerable 300WSM shoots the same bullet at 3090 fps, anincrease of 280 fps or 9% increase in velocity.

The novel ammunition achieves this performance increase with the samecaliber, same powder, same bullet (projectile mass) and same gun,achieving 8% improvement in velocity performance.

The present invention combines various disparate technologies to achievean all stainless steel/aluminum cased, polycarbonate/copper tipped,high-performance cartridge (small arms round). Notably, in exampleforms, the present invention accomplishes one or more of the following:(1) replaces brass shells with stainless steel and/or aluminum; (2)replaces lead-core copper-plated bullets (projectiles) with matrixprojectiles, such as polycarbonate bullets; (3) employs fluid dynamics(ARX) instead of hydrostatic shock (mushroomed, fragmented, shrapnellead); (4) achieves lightweight hi-performance cartridges that reduceweight compared to heavy traditional ammo, saving as much as 30-60% inweight; (5) increases projectile velocity 15-30%; (6) reduces recoil10-25%; and (7) eliminates lead and copper fouling in gun barrels, andin the air.

Additional Considerations

When making a shell casing of stainless steel, the stainless steel isharder, stiffer and less malleable than commonly used brass. This cancause unexpected problems when attempting to flare the case mouth as isa common practice in preparation to load a brass pistol case. First ofall, the stainless steel case mouth can be more difficult to flare or“bell” in the traditional manner.

Once the case mouth is flared to accommodate loading the projectile intothe case, it has been found that it can be very difficult to finish thecase into a crimp that is smooth and professional looking. In order tosmooth out the flare, a significant crimp may be required. In aPoly/Copper cast or molded bullet, the crimping can often result in ahairline fracture in the poly/copper projectile, which can cause theprojectile to break off flush with the crimp line at the case mouthduring loading and/or firing mode. This difficulty was overcome by anewly-developed loading method. In this new loading method, first, thestainless steel case mouth is not belled or flared, but leftstraight-walled. To insert the projectile into the case without a flaretypically requires precision alignment and very tight tolerances.

5. Additionally, almost all loading information heretofore has beenbased upon a substantially crimped bullet. Without a crimp, case mouthtension alone can greatly affect internal cartridge pressure and desiredvelocity. This crimpless design led the inventors to develop somecompletely new and unique ballistic loading data. The inventors in theend settled on the use of non-customary powder types with faster burningrates not usually associated with cartridges.

Another unforeseen problem was the use of 6061 and 7075 aluminum alloysfor the base of the two-piece case. As rifle caliber cases weredeveloped, several problems emerged which led the inventors to switch toa chrome molybdenum steel base component. While this steel alloy isrelatively expensive, the chrome moly steel accommodates higheroperating pressures of rifle calibers. Various other types of stainlesssteel can work well for the base as well.

The steel base, being considerably stronger than aluminum alloy, made itpossible and/or feasible to cut a deeper extractor groove into the shellbase. This feature has been found to be especially beneficial whenfiring full-auto fire military weapons and belt-fed weapons.

Ideally, a stainless steel should be chosen that is soft enough tostamp-form into a rifle casing, yet hard enough and strong enough towithstand the high pressures of a rifle cartridge. Finally, a custom,proprietary stainless steel similar to 316 stainless, with a 9.75%nickel content has been determined to be most suitable for thisapplication. The stainless steel for the casing could also be of otheralloys, such as 304, 305, 306, or 316 alloys.

The original poly/copper resin, manufactured and supplied by PolyOneCorporation, has been used satisfactorily in traditional brass-casedammo in the past. Upon the investigation of using PolyOne's resin in thesmall arms ammunition according to the present invention, projectileintegrity issues and deformation immediately became apparent at thehigher velocities produced by the new ammo. A new, higher strengthresin, consisting of a proprietary blend of nylon, epoxies and polymerswas formulated specifically for this new ammo.

Optionally, one can utilize metallics and heavy metals (other thancopper) in the resin compound. For example the use of a zinc-basedresin, an iron-oxide-based resin, a tungsten carbide-based resin, adepleted uranium based-resin, etc. all can be employed. This utilizes anew technique to create a homogenous blending of more than one heavymetal in the projectile resin.

Optionally, the primer base could also be made of stainless steel, suchas a 416 stainless steel alloy, for example. Optionally, the primer baseand the shell housing can both be made of 416 stainless steel alloy.Optionally, these two component portions of the casing can be made ofdifferent metals, such as having the shell housing made of one stainlesssteel alloy and the primer base made of aluminum or a differentstainless steel alloy (such as the 416 stainless steel alloy).

Also optionally, the projectile can be constructed with hBN (hexagonalBoron Nitride) powder to achieve a poly/molded projectile. This ultrafine hBN powder acts as a friction-reduction agent when applied, throughan optional steel/ceramic shot vibration/peening process, into the poresof the projectile. The use of hBN powder can provide multiple advantagesin this application, including: less friction between the projectile andthe barrel rifling, thus decreasing pressure, reducing barrel wear,increasing velocity, improving accuracy and minimizing the extremevelocity spread between many rounds. Optionally, other types ofanti-friction coatings or lubricants can be employed to provide similarcharacteristics or benefits to the projectile as the hBN, although thehBN is preferred.

Additional Benefits and Advantages

Initially, an observed advantage of the stainless steel case was a lessexpensive option to the common brass cased ammunition. (Brass isgenerally more expensive than stainless steel.) However, as pressure andvelocity tests were conducted, completely new loading data developed,and new loading techniques were adapted, more advantages began to berealized. First, the stainless steel casing can be made much thinnerthan a brass casing. The consistent outside dimension of each caliber iscritical as prescribed by SAAMI. The result with thinner stainless is alarger internal capacity in each caliber utilizing stainless steel. Thisallows for more powder, higher velocities and greater performance.

Additionally, previously it was not apparent how much energy the brasscase absorbs during the shot, as there was nothing else with which tocompare it. Testing of the new cartridge established that far lessenergy is absorbed by the stainless case, resulting in more energyavailable to propel the projectile down the barrel. The results havebeen impressive, often yielding more than a 10% increase in performanceover the exact same cartridge with a brass case.

Additionally, it was previously considered that poly/copper bullets,previously only used when loaded into a brass case, were ratherinaccurate, even at 100 yards. Upon testing the new ammo, yieldinghigher velocities, the projectiles were extremely accurate out to rangesin excess of 500 yards. Also contributing to this accuracy is thestainless case and the poly/copper bullet combination which produces anoptimum performance, which is not duplicated by any known combination ofbrass cases and poly/copper projectiles.

Other Observations:

The novel ammo results in less recoil due to the lighter weightpoly/copper projectile. Perceived recoil reduction was estimated at20-25%. However, actual reduction (measured) in recoil varied betweenabout 15% and 25%.

The novel ammo delivers much higher energy from each specific caliberbecause of the higher speed of the projectiles. For example, a normal 9mm defensive round, say a Hornady Critical Defense round, delivers a 124grain bullet at 1140 fps and creates approx. 332 ft lbs of energy. Theequivalent 9 mm round according to the invention delivers nearly 1800fps with a fluted 65 grain bullet, creating 460 ft/lbs of energy—moreenergy than a full-power 45 ACP (352 ft lbs). (This performance cannotbe duplicated by a brass-cased cartridge within safe and standard SAAMIpressures.

The novel ammo causes less barrel fouling or barrel wear. The ammo israther “clean”. Bore inspection after thousands of rounds prove to bevirtually clean, showing no evidence of any wear or tear on the chamber,barrel, or rifling.

The novel ammo allows for excellent terminal performance from thecombination of hydrostatic shock and dynamic fluid displacement. It isalso rather precise and accurate ammunition, far more so thanbrass-cased ammo with the same projectiles.

Advantageously, the ammo with its Poly/Copper projectile would beconsidered to be lead-free by the shooting industry and all known stateregulatory agencies.

While the invention has been shown and described in exemplary forms, itwill be apparent to those skilled in the art that many modifications,additions, and deletions can be made therein without departing from thespirit and scope of the invention as defined by the following claims.

What is claimed is:
 1. A small arms ammunition round, comprising: anon-brass casing comprising stainless steel; and a non-lead projectilehoused within the casing, the non-lead projectile comprising a matrix ofat least one epoxy, at least one non-epoxy polymer, and copper.
 2. Asmall arms ammunition round as claimed in claim 1 wherein the non-leadprojectile comprises copper particles.
 3. A small arms ammunition roundas claimed in claim 1 wherein the matrix projectile comprises purecopper.
 4. A small arms ammunition round as claimed in claim 1 whereinthe matrix projectile comprises tungsten.
 5. A small arms ammunitionround as claimed in claim 1 wherein the matrix projectile comprises acopper alloy.
 6. A small arms ammunition round as claimed in claim 1wherein the matrix projectile comprises a blend of copper and tungsten.7. A small arms ammunition round as claimed in claim 1 wherein thecasing comprises a stainless steel shell housing and an aluminum primerhousing press-fit together.
 8. A small arms ammunition round as claimedin claim 1 wherein the casing comprises a stainless steel shell housingand an chrome moly steel primer housing press-fit together.
 9. A smallarms ammunition round as claimed in claim 1 wherein the projectile has atapered nose with spiral flutes.
 10. A small arms ammunition round asclaimed in claim 1 wherein the copper/polymer matrix comprises a matrixof at least one epoxy, at least one metal, and at least one non-epoxypolymer.
 11. A small arms ammunition round as claimed in claim 1 whereinthe casing comprises a first portion and a primer portion press-fittogether.
 12. A small arms ammunition round as claimed in claim 1wherein at least a portion of the casing comprises a 416 stainless steelalloy.
 13. A small arms ammunition round as claimed in claim 1 whereinat least a primer portion of the casing comprises a 416 stainless steelalloy.
 14. A small arms ammunition round as claimed in claim 1 whereinthe projectile comprises hBN (hexagonal Boron Nitride) powder.
 15. Asmall arms ammunition round as claimed in claim 14 wherein the hBNpowder is incorporated into the projectile by a shot vibration/shotpeening process.
 16. A small arms ammunition round as claimed in claim 1wherein the at least one non-epoxy polymer comprises nylon.
 17. A smallarms ammunition round, comprising: a multi-piece, non-brass casing; anda non-lead projectile housed within the casing.
 18. A small armsammunition round as claimed in claim 17 wherein the non-brass casingcomprises a stainless steel casing.
 19. A small arms ammunition round asclaimed in claim 17 wherein the non-brass casing comprises an aluminumcasing.
 20. A small arms ammunition round as claimed in claim 19 whereinthe aluminum casing comprises an aluminum alloy.
 21. A small armsammunition round as claimed in claim 19 wherein the aluminum alloycasing comprises 7075 aluminum.
 22. A small arms ammunition round asclaimed in claim 19 wherein the aluminum alloy casing comprises 7078aluminum.
 23. A small arms ammunition round as claimed in claim 19wherein the aluminum casing comprises substantially pure aluminum.
 24. Asmall arms ammunition round as claimed in claim 17 wherein the non-leadprojectile comprises a metal/polymer matrix.
 25. A small arms ammunitionround as claimed in claim 24 wherein the metal/polymer matrix comprisesa matrix of at least one epoxy, at least one metal, and at least onenon-epoxy polymer.
 26. A small arms ammunition round as claimed in claim24 wherein the metal/polymer matrix comprises a matrix comprising epoxyand copper.
 27. A small arms ammunition round as claimed in claim 17wherein the projectile has a tapered nose with spiral flutes.
 28. Asmall arms ammunition round as claimed in claim 17 wherein theprojectile has a smooth tapered nose.
 29. A small arms ammunition roundas claimed in claim 25 wherein the at least one non-epoxy polymercomprises nylon.
 31. A small arms ammunition round as claimed in claim17 wherein at least a portion of the casing comprises a 416 stainlesssteel alloy.
 32. A small arms ammunition round as claimed in claim 17wherein at least a primer portion of the casing comprises a 416stainless steel alloy.
 33. A small arms ammunition round as claimed inclaim 17 wherein the projectile comprises hBN (hexagonal Boron Nitride)powder.
 34. A small arms ammunition round as claimed in claim 34 whereinthe hBN powder is incorporated into the projectile by a shotvibration/shot peening process.